Method of forming kapok yarn



Aug,f.11,1942.v w c. WATTS 2,292,500

` METHOD 0F FORMING KAPOK YARN Filed Dec. l2, 1941 mi grip:

Patented Aug. 1l, 1942 UNITED STATES T CEE-'ICE METHOD OF FORMING KAPOK YARN Application December 12, 1941,7Serial No. 422,634

3 Claims.

\ to several tropical genera of the family Bornbacaceoe, is valuable because of its lightness, high insulation value, resistance to moisture, etc. It has been employed for certain limited uses in a matted form. Its extremely short fibres have heretofore rendered it unadapted to be woven into textiles, and its use has been limited to the stufling of cushions, upholstery and other like uses. Its highly valuable use as a textile has been considered impossible because of the shortness and delicate character of the fibres.

An object of the present invention is to provide a method and means whereby kapok fabric can be produced. A further object is to produce a kapok fabric in which the fibres are compactly held in a woven, knitted, etc., structure without the use of adhesive or other materials which reduce the effectiveness of the kapok as an insulating, light and moisture-resistant material. A still further object is to provide a kapok strand adapted to be used with weaving or knitting machines of the type now employed for the forming of kapok fabric. Other specific objects and advantages will appear as the specification proceeds.

-The invention is illustrated, in a preferred embodiment, by the accompanying drawing, in

which- Figure 1 is a broken plan view of woven kapok fabric embodyingv my invention, one strand of the fabric being unraveled; Fig. 2, a similar View of fabric formed by knitting; and Fig. 3,

an enlarged detail view of a kapok-covered thread employed in the process. In the illustration given, ID designates a thread which may be formed of cotton, wool, silk or any other suitable material providing tensile strength. II designates a body of kapok rubbed upon the thread or otherwise secured about it. I2 designates a. strand of kapok-covered threads IIJ brought together first in parallel relation and then coiled or twisted while in strand form.

In the illustration shown in Fig. 1, the strands I2 are united in a weaving operation in which cotton, silk, or any other suitable threads I3 are interwoven with the strands I2. kapok-equipped strands I2 run in parallel lines Here the while the threadsI I3 extend transversely of the 55 fabric.

In the illustration given in Fig. 2, the strands I2 are identical with those shown in Fig, 1, but the strands are secured together by knitting threads I4 extending transversely of the fabric. Any suitable means for securing the threads I2 in a' fabric structure may be employed.

In the practice of my invention, I cause the single threads lli first to be covered separately by a coating II of kapok fibre. This may be done in any suitable apparatus. I prefer to rub the kapok onto and around each thread to form a mat covering the thread, as illustrated in Fig. 3. I avoid twisting or spinning the thread because this causes the peculiar short fibresiof the kapok to slide off the thread instead of becoming further attached to it. The untwisted threads with their loose covering of kapok are next brought together in strands, such as illustrated by the numeral I2. The strand of parallel fibres is then twisted as an entirely, providing a strand coil or twist as illustrated in Figs. 1 and 2. The strand twisting causes the loose kapok sheath on each thread to be gripped between the twisted threads and locked into firm union with the strand.

The resulting twisted strand I2 may be handled in Weaving machines, knitting machines, etc., without any substantial loss of fibre and formed into kapok fabric as illustrated in Figs. l and 2.' The blanket or fabric strip thus produced is rm, even and' uniform and of good texture. It may be employed in the forming of garments, used as Wrapping blankets, insulating linings for airplanes and other vehicles, refrigerators and other apparatus. The fabric wears well and can be handled without injury. When water strikes the fabric, it forms large globules which do not penetrate the material but, when an inclination is provided, roll off the fabric.

As already stated, in the fabrication of the strand, it is important that each thread, after being provided with its coating of kapok rubbed thereon, not be twisted or spun or handled to any unusual extent. The peculiar character of the kapok causes it to resist any substantial handling or manipulation while in this state. The reinforced thread cannot be handled, as Woolen or cotton reinforced threads. When formed, the threads are laid in parallel arrangement, brought together loosely and then coiled or twisted as a strand, the strand twisting producing a unitary, firm structure and providing a unit suitable for weaving and spinning in the 'usual manner and on the usual machines. For the purpose of clearness, I use the words Weaving, interweaving, woven and interwoven in the attached claims in a broad sense, indicating the uniting of the strands into fabric form by knitting, weaving, or other means.

In the above-described operation, the reinforced threads, after being brought together loosely, are twisted while limp into a strand to confine the kapok fibres between the threads. I further prefer to bring the kapok-coated threads together in parallel arrangement Without tension being exerted thereon, the threads then being brought together loosely and twisted While still not under tension into the strand described.

While I have, in the foregoing description,set forth certain preferred structures and certain steps in sequence, it will be understood that considerable variation may be made in the Vdetails of such structures and in such steps and Vthesequence thereof without departing from the spirit of my invention.

I claim:

1. The method of forming a kapokbre strand suitable for forming into'cloth, comprisingcovering individual'threads of relatively Vhigh Atensile strength with a coating of wkapok bres, laying the kapok-coated threads substantially in parallel arrangement without tension being exerted thereon, bringing together the coated threads loosely and twisting them while still not under tension into a strand to confine the kapok fibres between the threads.

2. The method of forming a kapok bre strand suitable for forming into cloth, comprising covering individual threads of relatively high tensile strength each with a coating of kapok bres, bringing the kapok-coated threads together loosely and then twisting them while limp into a strand to conine the kapok bres between the threads.

3. The method of forming a short-fibre strand suitable for weaving or knitting into a textile fabric which requires the covering of individual threads of relatively high tensile strength with a coating of short fibres resulting in fibre-coated threads, bringing together such fibre-coated threads in loose alignment, and then twisting the coated threads while limp into a strand to conne the short fibres between the threads and thereby producing va yarn suitable for weaving or knitting.

WALTER C. WATTS. 

